Composite backerboard articles for construction

ABSTRACT

A fabricated article made from two or more discrete sections of a single composite board. The composite board has a planar core with opposing first and second flat sides and a coating of solidified, cement-like mortar disposed on at least one side of the core. The coating has a reinforcement layer disposed therein. Form one or more shapes or cuts in the board that extend through one first side of the core and any coating thereon (with embedded reinforcement layer) and through the second side of the core, but not through the coating and reinforcement layer of the second side. Fabricate the article by bending the two or more discrete sections at the shape or cut and joining them in a fixed position by applying an adhesive to the shape or cut. Alternately, pieces of core, or pieces of core with coating, and, optionally, reinforcement, can be adhesively joined. One can also apply a coating of cement—like mortar, optionally, with an embedded reinforcement to the joined pieces.

BACKGROUND OF THE INVENTION

[0001] This invention relates to articles made from composite board, commonly known in the art as backerboard, or tile backerboard.

[0002] U.S. Pat. No. 5,961,900 discloses a method of manufacturing composite board whereby a continuous coat of mortar reinforced with glass cloth is laid onto a continuous core.

[0003] U.S. Pat. No. 5,350,544 discloses a method and apparatus for producing lightweight construction panels having a cementitious core layer surfaced with a layer of reinforcing fabric.

[0004] Composite boards produced by the methods of U.S. Pat. Nos. 5,961,900 and 5,350,544, both of which are hereby incorporated by reference, and by other methods, desirably provide satisfactory insulation of both noise and heat, have satisfactory mechanical properties, are relatively light in weight, smooth, and flat, and are made from a small amount of physical material. Composite boards such as these are used in various aspects of residential and commercial building construction, including tile installations.

[0005] A major use of these composite boards is in tile construction, where the composite backerboard is positioned between the substrate and the tile. Installation of the backerboard and the tile by present methods is laborious and time consuming, especially when the installation includes various corners, curbs, and wall inserts. A major contributing factor to the labor and time involved in this construction is installation of the backerboard in the comers, curbs, and wall inserts.

[0006] The current practice, as described in Setting Tile, by Michael Byrne, Taunton Books and Videos, 1995, pages 173-219 is to cut and form composite board backer articles on site, or use mud beds or other backer products. There are other products that attempt to overcome the difficulties of placing these pieces while maintaining the waterproof nature of the backerboard. All are time-consuming and do not adequately address waterproofing.

[0007] There has been a product available in parts of the Southeast United States, which is cut from large solid pieces of foam and coated with a cementitious material.

SUMMARY OF THE INVENTION

[0008] It would be desirable for the construction industry to have available various articles made from composite board that can be used in tile construction installations to eliminate the necessity of repeatedly, individually making various comers, curbs, and wall inserts.

[0009] This invention provides an article made from composite board comprising:

[0010] (A) a substantially planar core having a first flat side and opposite thereto a second flat side,

[0011] (B) a coating of solidified, cement-like mortar disposed on the second side or both the first and second sides of the core, and,

[0012] (C) embedded within the coating (B) of the second side, and, optionally, the coating of the first side, a reinforcement layer,

[0013] where the article comprises two or more discrete sections of composite board produced from a single composite board by forming one or more shapes or cuts in the board that extend through the first side of the core and any coating thereon and through the second side of the core, but not through the coating and reinforcement layer of the second side, the two or more discrete sections being bent at the shape or cut and joined in fixed position by an adhesive applied to the shape or cut. The shape or cut is desirably a V.

[0014] In another embodiment, this invention provides an article made from composite board comprising:

[0015] (A) a substantially planar core having a first flat side and opposite thereto a second flat side,

[0016] (B) a coating of solidified, cement-like mortar disposed on the second side or both the first and second sides of the core, and,

[0017] (C) embedded within the coating (B) of the second side, and, optionally, the coating of the first side, a reinforcement layer,

[0018] where the article comprises two or more discrete sections of composite board joined by an adhesive at a fixed angle, the discrete sections being pieces of core, or pieces of core with coating (B), and, optionally, reinforcement (C), and, optionally, with a coating (B), optionally, with embedded reinforcement (C), applied to the joined pieces.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1 shows a typical tile construction.

[0020]FIG. 2 shows a composite backerboard with one V.

[0021]FIG. 3 shows a tile construction at a corner with one V backerboard.

[0022]FIG. 4 shows a composite backerboard with two Vs.

[0023]FIG. 5 shows a tile construction at a corner with a two V backerboard.

[0024]FIG. 6 shows a V cutting pattern to make a corner article.

[0025]FIG. 7A shows the exterior of a corner article.

[0026]FIG. 7B shows the interior of a corner article.

[0027]FIG. 8 shows a tile curb construction.

[0028]FIG. 9 shows a cutting pattern for a rectangular insert article.

[0029]FIG. 10 shows a rectangular insert article.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] The invention relates to various shapes of composite backerboard articles that are useful to the construction industry. These products can be made by cutting and joining discrete sections of a flat backerboard into the required shape. A preferred backerboard used as the substrate for this invention is extruded polystyrene foam coated on both sides with a fiberglass mesh and cementitious coating. Products of this type are available from wedi GmbH (wedi Building Board), Lux Elements GmbH & Co KG and other European companies.

[0031] As used herein, “composite board”, “backerboard” and “composite backerboard” are equivalent, and all refer to one or another of the various composite boards useful in the practice of this invention.

[0032] The coatings on the sections of composite board are not critical, but must provide a bonding surface for attached finishing products or adhesives. The mesh reinforcement layer must be somewhat flexible and provide tensile strength to the product during fabrication and use. Coatings other than cementitious materials and fiberglass mesh can provide these properties, and, therefore, may be used in the practice of this invention.

[0033] The core may be expanded thermoset or thermoplastic beadboard or extruded foam or fibers, beads, flakes, strips, fragments of organic or inorganic material or both or a combination thereof. A preferred material is STYROFOAM® extruded polystyrene foam. Compacting a layer of beads, chips, flakes, fragments, etc. of organic or inorganic materials is also practical. This procedure will result in a core essentially as thick as the finished board and strong enough to be exposed to static or dynamic stress of the extent to be expected when employed for the purposes discussed herein.

[0034] It is of advantage when the layer of beads, chips, flakes, fragments, etc. of organic or inorganic materials is coated with an expanded extrudate for the extrudate to permeate or bind the beads etc. The result will be a core or sandwich of organic or inorganic materials wherein at least one surface of the organic or inorganic materials, which are not particularly strong mechanically, will be in contact with the more durable and homogeneous expanded extrudate.

[0035] The expanded extrudate can be polystyrene or glass, a recycled bulk or expanded extrudate, or a wood-bonding sheet. Other similar materials can also be employed. Some examples are recycled bulk or expanded and compressed recycled materials, expanded polyurethane, and such solid blends as wood-bonding and similar materials. It is essential in this event as well for the expanded-material core to be provided at some point with a rigid and reinforced sandwich structure that will render it not only fireproof but also able to have tiles, for example, cemented or otherwise fastened to it or to be plastered, wallpapered or painted.

[0036] The thickness of the core is relatively uncritical. It can be between a few millimeters (mm) and a few centimeters (cm), for example between 20 and 100 mm, depending on its purpose. The coating of mortar will generally be applied as economically as possible, just enough to cover the glass cloth or other reinforcing means.

[0037] It is of advantage for the layer of reinforced mortar to be very thin, as thin as 0.2 mm, for example. There is on the other hand essentially no upper limit for the thickness of the mortar coating, but desirably it is 1 cm or less, preferably 2 mm or less.

[0038] To make the shaped backerboard articles from composite board, make cuts in the flat composite backerboard to form shapes, preferably “V” shapes between discrete sections of composite board. Place a waterproof adhesive in the shape and fold the backerboard into the proper shape. The adhesive must be capable of adhering to the foam core of the composite backerboard, providing a waterproof bond stronger than the foam itself. The dimensions of the shape, preferably a V shape, determine the angle of the joint. For example, a 90-degree V will form a right angle shape upon bending and adhering the product. A 45-degree V will form a 45-degree bend in the shape of the article.

[0039] By properly placing the cuts forming the V's or other cut shapes, many shapes can be made, including articles shaped for corner applications, for edge applications, a curb for shower enclosures, and even complex shapes such as inset soap dish backers.

[0040] Coatings useful in the practice of this invention include traditional mortars, including various mixtures of cement, Portland cement, magnesia cement, alumina cement, lime, gypsum with sand and water, and various plastic materials which may be thermosets, such as rigid polyurethanes, or thermoplastics, especially engineering thermoplastics of sufficient strength and rigidity.

[0041] Materials useful as the reinforcement layer include woven or nonwoven glass cloth or fiber, aramid or polyester fabric or fiber, polyvinylchloride coated glass fiber yarns, metal gauze, including copper, aluminum and stainless steel, and thermoplastic and thermoset materials, such as polyolefins, nylon, polyvinylidene chloride in the form of woven or nonwoven cloth, fabric or fiber.

[0042] Materials useful as the adhesive include a wide variety of commonly available glues, caulks, adhesives, bonds and sealants as are used in the construction arts.

[0043]FIG. 1 shows typical tile construction, where a construction substrate 1 has applied to it a composite board 2 with coatings of solidified, reinforced, cement-like mortar 4 disposed on both the first and second sides of a core 3. Applied to the upper surface of the composite board is tile 5.

[0044]FIG. 2 shows a composite board 10 with a core 11, coatings of solidified, cement-like mortar 12 having embedded therein a reinforcement layer 13 on both a first side 15 of core 11 and second side 16 of core 11. The shape or cut 14 extends through the first side 15 of the core 11 and the coating 12 thereon, but not through the coating 12 and reinforcement layer 13 of the second side 16 to produce the two or more discrete sections 17 and 18.

[0045]FIG. 3 shows one finished article of this invention, an edge piece 33 produced from the composite board of FIG. 2 by applying an adhesive, 21 in FIG. 3, to the V shape or cut and bending the discrete sections to produce the article 33. It is shown used in tile construction with substrate 1 and tile 5.

[0046]FIG. 4 shows a composite board 20 used to produce a finished article as shown in use in tile construction in FIG. 5. Composite board 20 has a core 11, coatings of solidified, cement-like mortar 12 having embedded therein a reinforcement layer 13 on a the first side 15 of core 11 and second side 16 of core 11. The V shapes or cuts 14 extend through first side 15 of core 11 and the coating 12 thereon. As shown in FIG. 5, a finished article 20′, with adhesive 21 in the V's now bent and joined in fixed position thereby, is applied to the substrate 1 and covered with a bullnose piece of tile 22 and a flat tile 5 connected by grout 19. The use of two V's to produce the corner piece article provides a piece particularly adapted for use with bullnose tile pieces and other tile pieces with rounded edges. A gap 23 between bullnose tile 22 and finished article 20′ has better contact when applied to this backerboard article than it would to one with a square comer. Gap 23 is typically filled with a setting material when tile is applied. In the absence of the present invention, one is left with a sharp corner that dramatically reduces potential for proper placement of a rounded section of a bullnose tile. The use of the present invention allows bullnose tile placement with edges that line up with adjoining tiles. One can use more than two V's or cuts to provide a more rounded corner piece 20′ and further minimize gap 23 and enhance tile alignment.

[0047]FIG. 6 show a cutting pattern of V's, as dotted lines 31 on the surface a composite board 2 used to produce a corner piece shown with exterior view in FIG. 7A and interior view in FIG. 7B.

[0048]FIG. 8 shows an article used in construction to form a curb, which often is formed around 2×4's 35. Note that this article has with two double V cut comers 36.

[0049]FIG. 9 shows a cutting pattern used produce the finished article shown in FIG. 10, which is designed to provide a backer board for use in the construction of a recess shelf or soap dish. This article is of particular interest, because it is quite complex.

[0050] Even more complex articles can be produced, with multiple sets of V's, even those where, for one or more sets of V's, side one and side two are reversed in alternating fashion in the cutting pattern. That is, sections of composite board defining V's cut on a single surface will always fold inward at an acute angle in a finished article. However, if a set of V's on one side of board to produce sections of composite board is accompanied by a set of V's farther along on the reverse side of the board, the new section will define an angle reversing outward from the first rather than toward it. Thus, it is possible to produce various shaped articles with lips designed to fit recesses typically encountered in construction.

[0051] In alternative embodiments, the article of this invention is produced from individual, completely separated pieces of core or composite board, which are joined with adhesive to form the article. Various alternatives are possible, such as, for example, joining pieces of core followed by the application of the coating, either with or without the reinforcement layer; joining pieces of composite board with adhesive alone, or with additional reinforcement at the joints by means of the reinforcement layer with additional adhesive or a coating of mortar or both.

[0052] Production of the articles of this invention can be accomplished completely independently from the production of the composite board, or it may be combined with production of the composite board, or at least some aspects thereof.

EXAMPLES

[0053] L-shaped Product for the Edge of a Wall or Shelf

[0054] Make an article by cutting a 90-degree V-notch in the foam-based, cementitious-and fiberglass mesh-coated backerboard. Take care not to cut the mesh at the base of the V-notch. Place a waterproof adhesive, such as Chemcalk 915 from Bostik, in a continuous bead in the V-notch. Fold the product at the notch into the 90-degree shape and allow the adhesive to cure. Choose the thickness of the flat backerboard to match the thickness of the adjoining surface of the substrate when installed.

[0055] 3-sided Product for Corners

[0056] Fabricate an article by making perpendicular V-notch cuts in a backerboard like that used to make the L-shaped product. Completely remove one of the rectangular pieces and fold the remaining pieces to make the 3-sided product. Form the corner formed by placing the completely cut edges together and use a waterproof adhesive, as with the L-shaped product, to bond surfaces of the corner together. The corner can be reinforced with fiberglass mesh and/or cementitious material if desired to provide additional strength. The waterproof adhesive or cementitious material can be used to attach the fiberglass mesh across the joint.

[0057] Multifaceted Piece for Architectural uses such as Recessed Soap Dishes

[0058] Form an article by making V-notch cuts in appropriate places. Some notches may be cut on the reverse side of the piece so that the fold can be in the opposite direction. Use a waterproof adhesive as described above. Any joints formed by non-adjoining surfaces coming together during folding may be reinforced as described above for the corner. The part may be quite complex, with many joints and edges. Choose the part's shape to match the shape of the product to be attached, e.g. tile. Thus, the edge of a soap dish should be of a length to accommodate full pieces of tile. Where the tile piece covers the corner (bullnose or similar piece), the corner should be made from two 45-degree V-notches, three 30-degree V-notches or a greater number of V-notches, placed close together to make provide clearance for the back of the tile. 

What is claimed is:
 1. An article made from composite board comprising: (A) a substantially planar core having a first flat side and opposite thereto a second flat side, (B) a coating of solidified, cement-like mortar disposed on the second side or both the first and second sides of the core, and, (C) embedded within the coating (B) of the second side, and, optionally, the coating of the first side, a reinforcement layer, where the article comprises two or more discrete sections of composite board produced from a single composite board by forming one or more shapes or cuts in the board which extend through the first side of the core and any coating thereon and through the second side of the core, but not through the coating and reinforcement layer of the second side, the two or more discrete sections being bent at the shape or cut and joined in fixed position by an adhesive applied to the shape or cut.
 2. The article of claim 1 , wherein the core comprises expanded thermoset or thermoplastic beadboard or extruded foam or fibers, beads, flakes, strips, fragments of organic or inorganic material or both or a combination thereof.
 3. The article of claim 1 , wherein the core comprises expanded thermoset or thermoplastic beadboard or extruded foam.
 4. The article of claim 1 , wherein the core comprises extruded thermoplastic foam.
 5. The article of claim 4 , wherein the core comprises extruded polystyrene foam.
 6. An article made from composite board comprising: (A) a substantially planar core having a first flat side and opposite thereto a second flat side, (B) a coating of solidified, cement-like mortar disposed on the second side or both the first and second sides of the core, and, (C) embedded within the coating (B) of the second side, and, optionally, the coating of the first side, a reinforcement layer, where the article comprises two or more discrete sections of composite board joined by an adhesive at a fixed angle, the discrete sections being pieces of core, or pieces of core with coating (B), and, optionally, with reinforcement (C), and, optionally, a coating (B), optionally, with an embedded reinforcement (C), applied to the joined pieces.
 7. The article of claim 6 , wherein the article has a coating (B) with an and embedded reinforcement (C) applied to the joined pieces.
 8. The article of claim 6 , wherein the article has been produced by joining with adhesive pieces of core with coating (B) and reinforcement (C). 